Advanced Design and Development Services

Eterna Global Solutions
C-52 Block-C, Sector 80
Noida Uttar Pradesh,
201306, India

Sheet Metal Design & Development Services — Enclosure Engineering, DFM, and Prototype-to-Production in India

Eterna Global Solutions LLP is a Noida-based precision sheet metal manufacturer offering in-house design and development services for OEM enclosures, server racks, telecom cabinets, battery housings, and custom fabricated assemblies. Our engineering team uses SolidWorks 2D/3D CAD with production-linked nesting and post-processing workflows to convert customer concepts into manufacturing-ready outputs — typically within 5–10 working days from initial file receipt to approved 3D model.

We specialize in Design for Manufacturability (DFM) for CNC laser-cut and formed sheet metal parts. Every design is reviewed for bend feasibility, tolerance stack-up, hardware insertion access, material yield, and production repeatability before release. This approach has helped our OEM customers reduce first-article rejection rates by up to 40% compared to designs that skip DFM review, and shorten qualification cycles from an industry-typical 8–12 weeks down to 4–6 weeks for standard enclosure programs.

We support the full range — from a single prototype enclosure fabricated from a hand sketch, to recurring production programs of 500+ units/month with controlled revision releases. Materials include mild steel (CR/HR), galvanized steel (GI/GP), stainless steel 304/316, and aluminum grades, in thicknesses from 0.5 mm to 25.4 mm. All design, fabrication, powder coating, and assembly is completed at our Noida facility (C-52, Sector 80), operating 24 hours to support tight lead times.

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Design and development overview

Concept → DFM → manufacturable CAD → production release.

What we design

19″ server racks (9U–47U), telecom outdoor cabinets (IP55/IP65), Li-ion battery enclosures (IP68), wall-mount and floor-mount data racks, electrical panels, OEM brackets, trays, chassis, doors, and multi-part sheet metal assemblies up to 2,000 mm in length.

How we design

DFM-first CAD development in SolidWorks: bend radius validation (min. 1× material thickness), hardware zone planning for PEM/clinch inserts, tolerance intent per ISO 2768-m, access and clearance checks, flat pattern generation, and production hand-off with controlled revision packages.

Key differentiator: Because we are the manufacturer, not a design bureau, every model we produce is validated against our actual machine capabilities — our fiber laser (3015 format, ±0.05 mm repeatability), CNC press brakes (up to 3,100 mm bending length), and hardware insertion presses. Design and production are under one roof in Noida.

Design engineering at a glance

Quantified capabilities for buyer evaluation.

5–10 daysConcept to approved 3D model (typical)

±0.1 mmStandard design tolerance (ISO 2768-m)

15+File formats accepted (STEP, IGES, DXF, DWG, PDF…)

0.5–25.4 mmSheet thickness range (MS, SS, GI, Al)

3,015 mmMax laser cutting bed length

3,100 mmMax CNC bending length

24-hourFactory operation for urgent programs

40%Avg. reduction in first-article rejections with DFM

For procurement teams: These specifications help qualify Eterna during vendor evaluation. Our fiber laser cutting achieves ±0.05 mm repeatability on flat patterns, and CNC bending holds ±0.1 mm on formed dimensions for standard sheet metal thicknesses. Request a capability sheet at info@itiseterna.com.

Design tools and software stack (click to expand)

Production-linked CAD + nesting + ERP integration.

SolidWorks 2D/3D CADParametric modeling + assemblies

All enclosure and component modeling is done in SolidWorks with sheet metal-specific features enabled. We build parametric models so design changes propagate automatically to flat patterns, BOMs, and drawing outputs.

Sheet metal features: bends, flanges, hem, jog, lofted bends, and edge flanges with K-factor/bend allowance tables matched to our actual press brake tooling
Assembly modeling for fit, interference detection, door swing clearance, and 19″ rail alignment checks
Drawing outputs with GD&T per ISO 2768, critical-to-quality (CTQ) callouts, and first-article inspection dimensions
Supported input formats: native SolidWorks (.sldprt/.sldasm), STEP AP214, IGES, Parasolid, DXF, DWG, PDF, and hand sketches

Nesting & yield optimizationAmada-linked material planning

Our nesting software is linked directly to the fiber laser and CNC punch, optimizing sheet utilization for each production batch. Typical material yield improvement is 8–15% versus manual nesting for complex multi-part layouts.

Auto-nesting with common-line cutting to reduce scrap on large batches
Standard sheet sizes: 1,250 × 2,500 mm and 1,500 × 3,000 mm (custom available)
Batch strategy planning for recurring programs to maintain consistent outputs and reduce setup time
Process planning files exported directly to CNC blanking machines — no manual re-entry

Hardware & fastener planningPEM, clinch nuts, standoffs

Hardware insertion is planned at the design stage to prevent assembly issues in production. We stock standard PEM fasteners (M3–M10) and plan insertion sequences aligned to our Haeger press capabilities.

Clinch nuts, clinch studs, standoffs, cage nuts, and grounding inserts — placement validated in CAD for tool access and edge distance
Self-clinch hardware selection per PEM Engineering standards for material thickness and pull-through loads
Assembly sequence planning for serviceability: ensuring field-replaceable components remain accessible
Thread engagement validation for M-series fasteners used in 19″ rack mounting (EIA-310-E compliant)

ERP-linked production releaseRevision control + routing

Design outputs are released through our ERP system with full revision traceability. Each production order links back to a specific drawing revision, BOM version, and routing plan — preventing version mismatches between engineering and the shop floor.

Drawing revision tracking with change notes and approval gates
BOM (Bill of Materials) generation linked to inventory and procurement
Routing plans for laser, punch, bend, weld, hardware, coating, and assembly — auto-generated from design data
First-piece inspection checksheets generated from CTQ dimensions in the drawing

Buyer note: Because design, production, and ERP are integrated under one system at our Noida facility, we eliminate the file-transfer errors and communication gaps that commonly occur when design and manufacturing are at separate companies.

Deliverables buyers receive from engineering

Manufacturing-ready documentation package.

CAD models + production drawings

3D SolidWorks models with sheet metal features, flat patterns, and bend tables. 2D production drawings with GD&T, hardware callouts, finish specifications (RAL color, plating type), and first-article inspection dimensions. Exported in STEP, IGES, DXF, DWG, or PDF as required by your engineering team.

Manufacturing release package

Flat pattern DXFs for laser/punch, bend sequence instructions for press brake, hardware insertion plans, welding callouts (MIG/TIG/fiber laser weld), BOM with fastener specifications, and a routing plan covering all production stages from blanking through final assembly and packing.

DFM report

Written feedback on bend feasibility, minimum flange lengths, hardware edge distances, tolerance achievability, material grade suitability, and cost-reduction suggestions. Provided before production commitment so buyers can approve design changes early.

Prototype documentation

For first-article and pilot builds: dimensional inspection report, photo documentation of critical features, deviation log (if any), and sign-off checksheet. Typically delivered with the physical prototype within 2–3 weeks of design approval.

File compatibility: We accept and deliver in 15+ formats including STEP AP203/AP214, IGES, DXF, DWG, Parasolid (.x_t), native SolidWorks, PDF, and JPEG/PNG for visual references. If your team uses Creo, Inventor, CATIA, or other native formats, we can typically import via STEP.

Design-to-production workflow

6-stage process with defined checkpoints.

Input review & requirements capture

Day 1–2 • Application, environment, constraints

We review your files (CAD, PDF, sketch, or verbal brief) and document all requirements to prevent downstream ambiguity. This stage defines the scope before any CAD work begins.

Application context: indoor/outdoor installation, IP rating requirement (IP20 through IP68), corrosion environment, operating temperature range
Interface requirements: mounting method (wall/floor/rack), cable entry points, access panels, ventilation openings, lock specifications
Compliance standards: EIA-310-E for 19″ racks, IEC 60529 for IP ratings, IS 2062 / IS 1079 for material grades, RoHS if applicable
Finish requirements: RAL color, texture, plating type (zinc, nickel, passivation), or bare metal specification

3D modeling & fit validation

Day 3–6 • Clearances, assemblies, interference checks

We build the 3D model in SolidWorks using sheet metal features so the design inherently reflects real-world bending, forming, and hardware insertion constraints. Assembly modeling validates fit and function before any metal is cut.

Door swing arcs, hinge zones, lock engagement, 19″ rail alignment (if applicable), and ventilation/airflow logic
Hardware placement zones validated for tool access on Haeger press and manual insertion stations
Interference and clearance checks for internal components (servers, batteries, switches, PDUs)
Visual renders shared with customer for appearance and layout approval before proceeding to DFM

DFM refinement & tolerance review

Day 5–8 • Bends, yield, cost optimization

This is where the design is optimized for our actual production equipment. We align geometry to our press brake tooling, validate flat patterns against our laser bed, and identify cost-reduction opportunities — often saving 10–20% on unit cost through design changes alone.

Bend feasibility: minimum internal radius (typically 1×t for mild steel, 1.5×t for SS 304), minimum flange length, and bend-near-hole clearances
Tolerance stack-up analysis for multi-part assemblies — reducing cumulative error that causes fitment issues during assembly
Flat pattern and nesting approach for controlled batch output and improved material yield
Hardware edge-distance validation (min. 3× fastener diameter from edge) to prevent pull-through failures
Written DFM report issued to customer with recommended changes and cost impact

Prototype fabrication & first-article inspection

Day 8–15 • Physical validation before production

We fabricate a physical prototype using production-intent processes (not 3D printing — actual laser cutting, bending, welding, and hardware insertion) so the prototype represents what serial production will deliver.

First-article inspection (FAI) with dimensional measurements on CTQ features using calibrated instruments
Photo documentation of critical assembly stages, weld quality, and hardware fitment
Deviation log for any dimensions outside tolerance, with root cause and corrective action
Customer sign-off before production release — no serial production without prototype approval

Production release package

Day 12–18 • Files + BOM + routing + inspection plan

After prototype approval, we finalize the complete manufacturing release package. This package is locked to a specific revision and controls all downstream production.

2D production drawings (PDF + DWG), flat pattern DXFs, and 3D STEP files
Hardware BOM with part numbers, quantities, and supplier specifications
Routing plan: laser → punch → bend → hardware → weld → grind → coat → assemble → inspect → pack
In-process inspection checkpoints and final inspection criteria aligned to customer requirements

Ongoing revision management

Continuous • ECN process for production programs

For recurring production programs, we manage design revisions through a formal Engineering Change Notice (ECN) process. This prevents unapproved changes from reaching the shop floor and maintains traceability across production batches.

ECN log with change description, reason, cost impact, and customer approval
Old vs. new revision comparison in CAD for buyer review
ERP-linked revision lock — shop floor only receives the currently approved revision
Quarterly design reviews for high-volume programs to identify further cost or quality improvements

Typical timeline: Simple brackets and panels: 5–7 days from file to prototype. Standard enclosures (up to 42U): 10–15 days. Complex multi-part assemblies: 15–25 days. All timelines assume prompt file sharing and approval at each checkpoint.

Materials we design for

Sheet metal grades and thicknesses.

Ferrous metals

Cold Rolled Steel (CRC/CRCA): IS 513-D, 0.5–3.0 mm. Most common for indoor enclosures, server racks, and brackets. Hot Rolled Steel (HRC): IS 2062 Gr. E250, 2.0–6.0 mm. Used for heavy-duty frames, base plates, and structural members. Galvanized Steel (GI/GP): IS 277, 0.6–2.5 mm. Standard for outdoor telecom cabinets and battery enclosures requiring corrosion resistance. Stainless Steel: SS 304 and SS 316, 0.5–4.0 mm. Used for IP-rated outdoor enclosures, food-grade applications, and marine environments.

Non-ferrous metals

Aluminium: 5052-H32 and 6061-T6, 0.8–4.0 mm. Used for lightweight enclosures, heatsinks, and RF shielding applications where weight or conductivity matters. We can also work with pre-coated and pre-finished sheets (galvannealed, pre-painted) where specified.

Surface finishes available

Powder coating (in-house, RAL chart, AkzoNobel paints), zinc plating, nickel plating, passivation (SS), anodizing (Al), and brush/satin finish (SS 304). Standard color: RAL 7035 (light grey) for server racks, RAL 7032 for telecom. Custom RAL colors available with 5–7 day additional lead time.

Material sourcing: We source sheet metal from JSW, Tata Steel, SAIL, and POSCO-certified distributors. Mill test certificates (MTCs) available on request for traceable programs.

Program support & collaboration model

Transparent, buyer-friendly execution.

Dedicated project ownership

Every project — regardless of size — is assigned a designated project manager who serves as a single point of contact for estimation, design iterations, production scheduling, and delivery coordination. Communication via email, WhatsApp, or scheduled video calls as preferred by the buyer.

Prototype through volume production

We support the full lifecycle: single-unit prototypes for design validation, pilot runs of 10–50 units for field testing, and recurring production programs of 100–2,000+ units/month with stable pricing, controlled releases, and safety stock options at our Noida warehouse.

Industries we serve from this capability

Data centers and IT infrastructure, telecom operators and tower companies, Li-ion and VRLA battery OEMs, EV charging infrastructure, electrical panel builders, retail and interior design firms, and railway rolling stock programs. Each sector has specific compliance and testing requirements that we factor into the design stage.

Quality and compliance

Designs are reviewed against applicable standards before release: EIA-310-E for 19″ rack dimensions, IEC 60529 for IP ingress protection, IS 2062/IS 1079 for material grades. Our ERP system tracks every revision, inspection result, and customer approval for full audit traceability.

Ideal fit: OEMs and system integrators who need a single manufacturing partner for enclosure design + DFM review + fabrication + powder coating + hardware insertion + final assembly — all from one facility in Noida, India, with pricing 30–50% below equivalent European or US contract manufacturers.

Frequently asked questions

Answers for OEM procurement and engineering teams.

What file formats does Eterna accept for sheet metal design projects?+

We accept 15+ formats including STEP (AP203/AP214), IGES, DXF, DWG, native SolidWorks (.sldprt/.sldasm), Parasolid (.x_t), PDF drawings, and JPEG/PNG reference images. We can also start from hand sketches, napkin concepts, or verbal descriptions and convert them into fully detailed 3D CAD models and production-ready flat patterns.

Can you convert a 2D drawing or sketch into a 3D model?+

Yes. We regularly convert hand sketches, legacy 2D drawings (DXF/DWG/PDF), and even verbal descriptions into fully parametric 3D SolidWorks models. The 3D model allows us to validate form, fit, interference, and assembly before any material is cut — catching errors that are expensive to fix in production. Typical turnaround for 2D-to-3D conversion is 3–5 working days for standard enclosures.

What is DFM and why does it matter for sheet metal enclosures?+

Design for Manufacturability (DFM) is the process of reviewing a design to ensure it can be economically and repeatably produced using available manufacturing processes. For sheet metal, DFM covers bend radius feasibility, minimum flange lengths, hardware edge distances, hole-to-bend clearances, tolerance achievability, and material yield optimization. At Eterna, DFM review has reduced our customers' first-article rejection rates by approximately 40% and shortened qualification cycles from 8–12 weeks to 4–6 weeks on average.

What tolerances can Eterna hold on sheet metal parts?+

Standard tolerance is ±0.1 mm on formed dimensions (per ISO 2768-m) and ±0.05 mm on laser-cut flat features. For tighter requirements, we evaluate on a case-by-case basis depending on material type, thickness, and part geometry. Tolerance stack-up analysis is included in our DFM review for multi-part assemblies to prevent cumulative errors during assembly.

How long does the design-to-prototype cycle take?+

Simple brackets and panels: 5–7 working days from file receipt to physical prototype. Standard server racks and enclosures (up to 42U): 10–15 working days. Complex multi-part assemblies with custom tooling: 15–25 working days. These timelines include 3D modeling, DFM review, customer approval, and fabrication of the physical prototype using production-intent processes (laser, bend, weld, hardware, coating).

Can Eterna handle both prototypes and volume production?+

Yes. We support the full lifecycle: single-unit prototypes for design validation, pilot batches of 10–50 units for field testing, and recurring serial production of 100–2,000+ units per month. Our ERP system manages revision control and production routing so the design that was approved during prototyping is exactly what gets manufactured at volume — with no undocumented changes.

What sheet metal materials and thicknesses does Eterna work with?+

We process mild steel (CRC/CRCA per IS 513-D, HRC per IS 2062), galvanized steel (GI/GP per IS 277), stainless steel (SS 304 and SS 316), and aluminium (5052-H32, 6061-T6) in thicknesses from 0.5 mm to 25.4 mm. Material is sourced from JSW, Tata Steel, SAIL, and POSCO-certified distributors. Mill test certificates are available on request for traceable programs.

How does Eterna's pricing compare to international contract manufacturers?+

Our pricing for design, fabrication, and assembly is typically 30–50% below equivalent manufacturers in Europe, US, or East Asia, while maintaining export-ready quality standards. We provide detailed cost breakdowns (material, labor, finishing, hardware, packing) so buyers can evaluate transparently. Request a quotation at info@itiseterna.com or through our contact page.

Does Eterna manufacture 19-inch server racks and data center enclosures?+

Yes. We design and manufacture 19″ EIA-310-E compliant server racks and data rack enclosures from 9U to 47U in floor-mount and wall-mount configurations. Standard depths available: 600 mm, 800 mm, 1,000 mm, and 1,100 mm. Enclosures are manufactured in galvanized steel or CRC with powder coating, and include features like cable management, ventilation panels, 3/4-point locking, adjustable 19″ mounting rails, and caster/leveling feet.

Where is Eterna located and what are the factory operating hours?+

Our manufacturing facility is at C-52, Block-C, Sector 80, Noida, Uttar Pradesh 201306, India. The factory operates 24 hours to support urgent production schedules and tight delivery timelines. For design consultations and project inquiries, reach us at info@itiseterna.com or +91 88004 99646.

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